Method and apparatus for sealing two moving webs of material together, which webs have portions which are non-planar

ABSTRACT

A method and apparatus for pleating or otherwise shaping a web are described herein. The method and apparatus may have numerous applications. In some embodiments, the method and apparatus are used in the formation, filling, and sealing of unit dose packages for consumer products. A method and apparatus for forming sealing two moving webs together, which webs have portions that are non-planar are also described herein.

FIELD

A method and apparatus for pleating or otherwise shaping a web aredescribed herein. The method and apparatus have numerous applications.In some cases, the method and apparatus are used as part of a process offorming, filling, and sealing unit dose packages for consumer products.A method and apparatus for sealing two moving webs of material together,which webs of material have portions which are non-planar, are alsodescribed herein.

BACKGROUND

Methods for pleating or otherwise shaping a web can be used for avariety of purposes. Pleated webs can, for example, be useful in theconstruction of diapers and other absorbent articles, filters, windowshades, and other articles. Methods of pleating webs are described in:U.S. Pat. No. 2,655,978, Gonda, et al.; U.S. Pat. No. 3,066,932,Greiner, et al; U.S. Pat. No. 3,165,310, Peterson; U.S. Pat. No.3,401,927, Frick, et al.; U.S. Pat. No. 3,784,186, Lenthall, et al.;U.S. Pat. No. 5,589,014, Hicks; U.S. Pat. No. 4,170,347, Lewis; U.S.Pat. No. 7,235,115, Duffy, et al.; U.S. Pat. No. 7,963,899 B2, Papsdorf,et al.; EP 0364084 A1; Indian Patent Publication 189471; and UK Patent 1433 910. In addition, a company by the name of Former Fab makes a devicefor corrugating a web. The webs that can be formed by its equipment arefound on the websitewww.former-fab.de/en/ideas-innovations/longitudinal-corrugating-technology.

Applicants have found the need for an improved process for shaping a webin an area in which webs are typically more randomly shaped—in verticalforming, filling and sealing (VFFS) processes for making packages forunit doses of liquid products. Unit doses of liquid products such asshampoo and hair conditioner are often placed in relatively thin, flatpackages known as sachets. Such sachets are typically provided withwater vapor barrier properties to prevent water loss from the product inthe package over time. Sachets of this type are generally made usingvertical forming, filling and sealing (VFFS) processes.

Current processes exist for vertical forming, filling and sealing, bothintermittently and continuously. Vertical forming, filling and sealing(VFFS) processes typically employ fill nozzles that are inserted inbetween two layers of material used to form the package. Current VFFSmachines may have up to twelve nozzles lined up in a row across thewidth of the two webs of material in order to form and fill twelvesachets at the same time. These processes rely on the webs of materialbeing forced together between the nozzles and held apart by the nozzlesin order to create a space into which the product is dispensed by thenozzles. When the webs are forced together between nozzles, longitudinalseals are formed between the webs to close the sides of the sachets, andtransverse seals are formed between each dose dispensed by the nozzles.

One problem with existing VFFS systems is that reliance upon the webs ofmaterial forming a space to dispense product as they pass around thenozzles is not precise, and can result in uneven widths of materialforming different sides of the sachets. Thus, the material from one ofthe webs that forms the front of the sachet may have a different widththan the material from the other web of material that forms the back ofthe sachet. This can lead to wrinkling of the sachets. Further, thewrinkling of webs can interfere with the formation of the transverseseals, so that the materials are not completely sealed together, leadingto leaky sachets.

The search for improved methods and apparatuses for pleating orotherwise shaping a web, as well as improved package forming processeshas, therefore, continued.

SUMMARY

A method and apparatus for pleating or otherwise shaping a web aredescribed herein. The method involves shaping a web that is moving in amachine direction. The method includes providing a forming guide whichcomprises a web-facing surface. The web-facing surface of the formingguide may be configured to provide a substantially equal path lengthacross the width of its web-facing surface. The web is formed by passingthe web over and at least partially in contact with the web-facingsurface of the forming guide to form longitudinally-oriented folds inthe web.

The method and apparatus may have numerous applications. In some cases,the method and apparatus are used in the formation, filling, and sealingof unit dose packages for consumer products. The method may comprisefeeding a first web of material and a second web of material into apackage forming apparatus in a machine direction. The package formingapparatus comprises at least one nozzle for dispensing a product inbetween the webs. The method comprises passing at least one of the firstand second webs of material adjacent to a forming guide to at leasttemporarily shape at least one of the first and second webs of materialacross the width of the same to space at least a portion of at least oneof the first and second webs of material away from the nozzle. A productmay be dispensed between the webs of material using the nozzle, andportions of the webs of material can be sealed together with the producttherebetween to form a package containing the product.

A method and apparatus for sealing two moving webs of material together,which webs of material have portions which are non-planar, are alsodescribed herein. The method comprises feeding a first web of materialand a second web of material into an apparatus in a machine directiongenerally parallel to each other along at least a portion of theirlengths. At least one of the webs of material has non-planar portionstherein that are formed across the width of the web. The methodcomprises providing a component having a web-contacting surface with atleast one recess therein, and forcing at least a portion of the websinto the recess in the web-contacting surface of the component with therecess therein in order to stretch and flatten at least some of thenon-planar portions in the webs; and sealing portions of the webs ofmaterial together across the flattened non-planar portions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example of a web passing over a prior art folding board toform a single pleat in a web.

FIG. 2 is an example of a web passing over a plurality of prior artfolding boards arranged side-by-side in an attempt to produce multiplepleats in a web.

FIG. 3 is a perspective view of one example forming apparatus includinga forming guide for shaping a web.

FIG. 4 is a plan view of another example of a forming guide.

FIG. 5 is a perspective view of a portion of a forming guide showing theconcept of equal path length forming.

FIG. 5A is a plan view of the portion of a forming guide shown in FIG.5.

FIG. 6 is a schematic end view showing how a forming guide and a matingcomponent can be positioned relative to each other with a webtherebetween.

FIG. 7 is a fragmented perspective view of the configuration of a webbefore and after passing through the forming apparatus.

FIG. 8 is a perspective view of an example of a forming guide comprisinga second region with rollers.

FIG. 9 is a schematic front view of one embodiment of a sachet.

FIG. 10 is a schematic perspective view of a single lane verticalforming, filling, and sealing process.

FIG. 11 is a schematic perspective view of a multiple lane verticalforming, filling, and sealing process.

FIG. 12 is a schematic cross-sectional view of a portion of the webssurrounding the nozzles of the multiple lane vertical forming, filling,and sealing apparatus.

FIG. 13 is a schematic perspective view of one embodiment of a turningguide for turning one of the shaped webs of material.

FIG. 14 is a schematic perspective view of another embodiment of aturning guide for turning one of the shaped webs of material.

FIG. 15A is a schematic cross-sectional view of a shaped pair of webs inbetween prior art cross-machine direction sealing bars, which are in afirst position in a sealing sequence.

FIG. 15B is a schematic cross-sectional view of a shaped pair of webs inbetween prior art cross-machine direction sealing bars, which are in asecond position in a sealing sequence.

FIG. 15C is a schematic cross-sectional view of a shaped pair of webs inbetween prior art cross-machine direction sealing bars, which are in athird position in a sealing sequence.

FIG. 15D is a schematic cross-sectional view of a shaped pair of webs inbetween prior art cross-machine direction sealing bars, which are in afourth position in a sealing sequence.

FIG. 16A is a schematic cross-sectional view of a shaped pair of webs inbetween a new apparatus for forming cross-machine direction seals, whichis in a first position in a sealing sequence.

FIG. 16B is a schematic cross-sectional view of the apparatus shown inFIG. 16A, which is in a second position in a sealing sequence.

FIG. 16C is a schematic cross-sectional view of the apparatus shown inFIG. 16A, which is in a third position in a sealing sequence.

FIG. 17 is a plan view (looking in the direction that the webs willtravel) of an alternative mechanism for forming cross-machine directionseals.

DETAILED DESCRIPTION

A method and apparatus for pleating or otherwise shaping a web aredescribed herein. The term “shaping”, as used herein, refers to alteringthe configuration of a planar web in a controlled manner. The term“shaping” includes, but not limited to: forming the web withoutnecessarily forming a fold in the same; at least partially folding theweb without either forming a crease in the web or doubling over the webon itself; folding a portion of the web onto itself; and formingmultiple side-by-side folds or pleats in the web. The method andapparatus have numerous applications.

FIG. 1 is an example of a web 10 passing over a prior art folding boardto form a single pleat in the moving web. The arrow represents thedirection of movement of the web, which will be referred to as themachine direction (or “MD”). The direction perpendicular to the machinedirection in the plane of the incoming unfolded web is known as thecross-machine direction (or “CD”). The folding board used to form theweb shown in FIG. 1, for reasons explained below, is not suitable forforming multiple side-by-side pleats in a web.

FIG. 2 is an example of a web passing over a modified prior art foldingapparatus comprising three adjacent prior art folding boards arranged inan effort to produce multiple pleats in a web 10. As shown in FIG. 2, itwas considered to place a series of the prior art folding board shapesside-by-side to produce multiple pleats in a web, but this requires theweb to be split (or slit) between each pleat such as at points P, whichwas not desired. The web will typically not be able to stretchsufficiently in the cross-machine direction to remain pleated and stillspan between these side-by-side folding boards. For this reason, such afolding apparatus design is unsuitable for uses in which the apparatusis required to form multiple side-by-side pleats in a single web.

The Forming Apparatus

FIG. 3 shows one example of a forming apparatus 20 for pleating orotherwise shaping a web as described herein. The forming apparatus 20comprises a forming guide 22 and a device or a mechanism for maintainingthe web at least partially in contact with the forming guide 22. In somecases, the device for maintaining the web at least partially in contactwith the forming guide 22 may comprise an optional mating component 24.The forming guide 22 may comprise two side edges 26, an upstream end 28having an end edge, a downstream end 30 having an end edge, a web-facingsurface 32 and an opposing surface 34. The configuration of theweb-facing surface 32 of the forming guide 22 is described in greaterdetail below. The opposing surface 34 can be of any suitableconfiguration including, but not limited to: flat (as shown in FIG. 3),corrugated (as shown in FIG. 6), or angled or curved (as shown in FIGS.13 and 14).

It should be understood that while the forming apparatus 20 shown inFIG. 3 is configured to form multiple side-by-side temporary pleats in aweb, the forming guide 22 can be in numerous other configurations. Suchother configurations include, but are not limited to those in which: theforming guide 22 is configured to: shape (or “form”) the web; provide asingle fold or pleat in a web; at least partially fold the web withouteither forming a crease in the web or doubling over the web on itself;and fold or pleat the web. In any case, the web will be bent in thecross-machine direction about at least one generally machinedirection-oriented axis. The forming apparatus 20 can, as discussed,form a plurality of pleats in the web. In some processes, the fold(s)can be permanently formed into the web. In other processes, the fold(s)may only be temporarily formed, so that no permanent crease is formed inthe web.

In the embodiment shown in FIG. 3, the web-facing surface 32 of theforming guide 22 comprises a first region (or “downstream region”) 36and a second region (or “upstream region”) 38. The first region 36 andsecond region 38 can have any suitable plan view configurations. In theexample of the forming guide 22 shown, the first region 36 and secondregion 38 have a boundary therebetween. In this case, the boundary is adiagonal boundary 40. The diagonal boundary 40 can be thought of asseparating the web-facing surface 32 of the forming guide 22 into twogenerally triangular fields when viewed from above (plan view). Thesecomprise a first triangular field that comprises the first region 36,and the second triangular field that comprises the second region 38.

As shown in FIG. 3, the first region 36 may comprise at least twoprojections (or “raised elements”) that are disposed at a greaterelevation outward from the web-facing surface 32 of the forming guide 22than other portions of the forming guide. The projections are spacedapart from each other in the cross-machine direction. The first region36 of the web-facing surface 32 further comprise at least one depressionin the web-facing surface 32 that is located between the projections.The first region 36 may comprise a plurality of alternating and adjacentprojections and depressions in the web-facing surface 32. Theprojections have a length and a width. The length of the projections islonger than the width of the projections. In the example of the formingguide 22 shown in FIG. 3, the projections are in the form of ridges 42and the depressions are in the form of valleys 44 having their longer(or length) dimensions that are generally oriented in the machinedirection. These may be referred to as a first group of ridges andvalleys. The first group of ridges 42 and valleys 44 are located atleast adjacent to the downstream end 30 of the forming guide 22.

The triangular plan view field formed by the first region 36 in theembodiment shown in FIG. 3 may be considered to have a base, B1, and apeak, P1. The base B1 of the triangular field is located adjacent thedownstream portion of the forming guide 22, and the peak P1 of thetriangular field is located adjacent the upstream portion of the formingguide. It should be understood, however, that the configuration of thefirst region 36 is not limited to a generally triangular configuration,and numerous other configurations are possible. In addition, when it issaid that the ridges 42 and valleys 44 are generally oriented in themachine direction, this includes orientations that are in the machinedirection, as well as those that are at an angle A1 of less than orequal to about 45°, alternatively between about 1 and 10°, relative tothe machine direction.

The second region 38 may comprise at least two second region projections(or “raised elements”) that are disposed at a greater elevation outwardfrom the web-facing surface 32 of the forming guide 22 than otherportions of the forming guide in the second region. These second regionprojections are spaced apart from each other in the machine direction.The second region 38 of the web-facing surface 32 further comprise atleast one depression in the web-facing surface 32 that is locatedbetween the projections. The web-facing surface 32 of the second region38 may comprise a plurality of alternating and adjacent projections anddepressions. The second region projections have a length and a width.The length of the second region projections is longer than the width ofthe second region projections. In the example of the forming guide 22shown in FIG. 3, the projections are in the form of ridges and thedepressions are in the form of valleys having their longer (or length)dimensions that are generally oriented in the cross-machine direction.These may be referred to as a second group of ridges 46 and valleys 48.The second group of ridges 46 and valleys 48 are located at leastadjacent to the upstream end 28 of the forming guide 22. In someembodiments, the cross-sections of the generally cross-machinedirection-oriented projections and depressions in the second region 38viewed in the cross-machine direction may, be the same as, or similar tothe cross-sections of the MD-oriented ridges and valleys in the firstregion when the latter are viewed in the MD. In other embodiments, thecross-sections of these elements of the first and second regions 36 and38 may differ.

The triangular plan view field formed by the second region 38 may beconsidered to have a base, B2, and a peak, P2. The base B2 of thetriangular field is located adjacent the upstream portion of the formingguide, and the peak P2 of the triangular field is located adjacent thedownstream portion of the forming guide. It should be understood,however, that the configuration of the second region 38 is not limitedto a generally triangular configuration, and numerous otherconfigurations are possible. In addition, when it is said that theridges 46 and valleys 48 in the second region 38 are “generallyoriented” in the cross-machine direction, this includes orientationsthat run at angles A2 between about 0°-45° relative to the cross-machinedirection. Angles that run in the cross-machine direction (that is, at90° relative to the machine direction) are desirable since other anglestend to drag on the web and cause the web to move to the side. This cancreate the need for devices to be added to the forming apparatus inorder to “track” the web.

As shown in FIG. 4, the projections in the second region 38 may beoriented so that their length dimension is at an acute (less than 90°)angle A3 relative to the generally machine direction-oriented ridges 42in the first region 36. Suitable angles, A3, range from between about45° and about 89°, alternatively between about 70° and about 89°. Lesserangles can also be used; however, this will change the depth to whichpleats are formed. At the boundary 40, the projections in the secondregion 38 align with the ridges 42 in the first region 36, and thedepressions in the second region 38 align with the valleys 44 in thefirst region 36. The projections in the second region 38 may, or maynot, abut with the ridges 42 in the first region 36. In the exampleshown, the projections in the second region (second group of ridges 46)abut with the ridges 42 along the diagonal boundary 40.

The orientation of the web can also be changed as it passes over theforming guide 22. The orientation of web is based on the orientation ofthe edges of web. The web can have an incoming machine directionorientation MDI, and an outgoing machine direction orientation MDO thatare typically different. For instance, FIG. 4 shows that the secondregion projections, such as ridges 46, can be set at an angle that runsat about 90° relative to the incoming machine direction orientation MDI(that is, the ridges 46 run in the cross-machine direction), and the web(not shown) can have an outgoing machine direction orientation MDO, thatis at an angle A4 that differs from the incoming machine directionorientation MDI. In this case, the angle A3 is complementary to theoutgoing machine direction orientation MDO angle A4 (both angles combineto form a 90° angle).

As shown in FIG. 5, the web-facing surface 32 of the forming guide 22may be configured to provide a substantially equal path length acrossthe width of the web-facing surface 32. The path length is measuredthrough a series of points, each point being equidistant from one sideedge of a web traveling over the forming guide 22 in the machinedirection. For example, FIG. 5 shows three parallel paths 52A, 52B, and52C that follow the contour of the web-facing surface 32 of the formingguide 22. If the wavy lines representing these paths (imagineinextensible strings) were lifted out of the surface of the formingguide 22 and straightened out to lie in the same plane, they would eachbe of the same length. It should also be noted that whenever a segmentof one line is on the same plane as a segment of another line (such asat the places marked by the double hash lines), they are parallel inthat plane and also parallel to the edge of the web. As shown in FIG. 5,the straight planar distance measured from one end of the line 52C tothe other end of the line 52C is designated Y, and the straight planardistance from one end of the line 52A to the other end of the line 52Ais designated X.

In this case, as shown best in FIG. 5A, distance Y is shorter thandistance X. The upstream ends of X and Y have a common machine directionstarting position (or “starting line”) S. The downstream ends have acommon machine direction finishing position. However, the finishingpositions lie along a line (a “finish line”), F, that is at an angle tothe “starting line” S. The finish line F is perpendicular to the ridges42 and grooves 44 in the downstream region 36 and to the edges of a webpassing over the forming guide 22. Therefore, although the line 52C hasmore bends in it, when the two lines 52A and 52C are straightened out,they have the same straight length.

This equal path-length web-facing surface 32 provides the web withconstant strain across the (cross-machine direction) width of the web,promoting even distribution of material in all depressions. The web,thus, also has an equal surface path length therein. This ensures thatsome portions of the web are not stretched/strained more than otherportions of the web. This also ensures that the web remains relativelytight against the forming guide 22 and reduces bagginess that would leadto wrinkles in the web.

As shown in FIG. 3, in order to assist in making a web at leastpartially follow the shape of the forming guide 22, a mating component24 can be positioned in a face-to-face relationship with the formingguide 22. The mating component 24 is shown in an open, non-matingposition in FIG. 3 for purposes of illustration. FIG. 3 shows theforming apparatus 20 arranged with hinges so that the forming guide 22and mating component 24 can be opened for cleaning. The mating component24 has a shaped web-facing surface that mates with the web-facingsurface 32 of the forming guide 22. The mating component 24 can haveany, or all, of the elements that are found on the forming guide 22.Thus, the mating component 24 can comprise two side edges 56, anupstream end 58, a downstream end 60, a web-facing surface 62, anopposing surface 64, a first region 66, a second region 68, a boundary70, a first set of ridges 72 and valleys 74 in the first region, and asecond set of ridges 76 and valleys 78 in the second region. The matingcomponent 24 may have any suitable web-facing surface configuration thatis capable of mating with the web-facing surface 32 of the forming guide22. In the example shown, the mating component 24 has a surfaceconfiguration that comprises a similar pattern of ridges and valleys asthat of the forming guide 22, but is offset so that the ridges 72 of themating component align with the valleys 44 of the forming guide 22, andthe ridges 42 of the forming guide 22 align with the valleys 74 of themating component 24.

As shown in FIG. 6, when in use, the two mating shaped surfaces 32 and62 are positioned slightly apart in order to force the web 10 to atleast partially follow the contours of the shaped surfaces. The twomating shaped surfaces 32 and 62 can be spaced apart any suitabledistance to form a gap, G, therebetween. The gap G can, for example, beabout 1 mm. The web 10 passes between this gap such that the peaks ofthe shaped surfaces push the web 10 toward the valleys of the oppositeshaped surface, forcing the web 10 into the desired shape.

The web 10 can take the general shape of the shaped surfaces. When it issaid that the web 10 can take the general shape of the shape of theshaped surfaces 32 and 62, as shown in FIG. 6, the web 10 may, but neednot conform exactly to the configuration of the shaped surfaces 32 and62. For example, as shown in FIG. 6, the web 10 may only contact theridges (or other raised elements) 42 and 72, and may not extend into thevalleys 44 and 74. Thus, the web 10 can be considered to be at leastpartially in contact with the web-facing surface of the forming guide.When the web 10 is moved through the forming apparatus 20, it canmaintain very nearly equal strain throughout. In at least some cases,the flat incoming web can be folded along the peaks and valleys of theforming apparatus as shown and all portions of the web between the peaksmay maintain their original shape. In such cases, the web may besubstantially free from stretching between fold lines.

In operation, the web 10 will typically have a substantially planar(flat) incoming configuration. The web 10 first passes through a seriesof generally CD-oriented pleat-forming shapes connected to generallyMD-oriented pleat-forming shapes. Passing the web 10 through the formingapparatus 20 causes the web 10 to first take the general configurationof the web-facing surface of the second region 38, and then for machinedirection-oriented pleats to be formed progressively in thecross-machine direction as the web 10 proceeds downstream. As shown inFIG. 6, all of the pleat peaks may lie in the plane of the flat incomingsection of the web. All pleat valleys may lie in a common plane parallelto and at a distance “DP” (depth of pleat) below the plane of the peaks.FIG. 7 shows one example of what a web 10 may look like when it entersthe forming apparatus 20, and after it has passed through the formingapparatus. The web 10 has a plurality of machine-direction orientedridges 82 and valleys 84 that have MD-oriented fold lines 85 definingthe same.

Numerous alternative embodiments of the forming apparatus 20 and methodare possible. A non-limiting number of these are described below. FIG. 8shows a second example of a forming guide 22. In this case, the formingguide 22 comprises a second region 38 in which the ridges on thepreviously shown forming guide (which are oriented generally in thecross-machine direction) are replaced with rotatable idler rollers 80.This greatly reduces the friction developed on the web 10 compared witha web passing through a fixed surface forming apparatus. Although therollers 80 can be oriented at an angle of less than 90 degrees relativeto the machine direction, it is desirable that rollers 80 are orientedwith their axis of rotation, A, at an angle of 90° relative to theincoming machine direction MDI.

In other embodiments, rather than having a forming apparatus 20 thatcomprises a forming guide 22 and a mating component, some othermechanism can be used to force the web 10 to follow the shape of theforming guide 22. For example, air pressure can be applied to the top ofthe web to force the web 10 to follow the shape of the forming guide 22.In other embodiments, rather than applying air pressure on top of theweb, the forming guide 22 can have holes therein, and a vacuum can bedrawn through the holes in order to hold the web in place on the formingguide 22.

The methods for pleating or otherwise shaping a web described herein canbe used for a variety of purposes including, but not limited to: in themanufacture of diapers and other absorbent articles, filters, windowshades, and other articles, and as described below, in the formation ofpackages.

Use of the Forming Apparatus to Make Unit Dose Packages

(1) Unit Dose Packages

In some cases, the method and apparatus may be used in the formation,filling, and sealing of unit dose packages for consumer products.Although the method and apparatus is illustrated herein in the contextof producing unit dose packages, it should be understood that this ismerely one example of the use of the method and apparatus. The methodand apparatus can be used in any suitable process.

The unit dose package formed by the method and apparatus can be in anysuitable configuration. The contents of the package can be in anysuitable form including, but not limited to solids, liquids, pastes, andpowders. The term “fluid” may be used herein to include both liquids andpastes.

In certain embodiments, the unit dose packages comprise sachets that arefilled with products which may include personal care products orhousehold care products including, but not limited to: shampoo, hairconditioners, hair colorants (dyes and/or developers), laundrydetergents, fabric softeners, dishwashing detergents, and tooth paste.The sachets can contain other types of products including, but notlimited to food products such as ketchup, mustard, mayonnaise, andorange juice. Such sachets are typically relatively thin and flat, andin some cases, are provided with water vapor barrier properties toprevent water loss from the product in the package over time, or waterintrusion into the product from outside the package.

FIG. 9 shows one non-limiting example of a package that is in the formof a prior art sachet 90. The sachet 90 has a front 92, a back 94, aperiphery 96, two sides 98, a top 100, and a bottom 102. The sachet 90further has a seal 104 around the periphery. The sachet may be in anysuitable configuration including, but not limited to the rectangularshape shown. The sachet may have any suitable dimensions. In oneembodiment, the sachet is 48 mm×70 mm, and has a sealed area that is 5mm in width around all four sides. The dimensions of the pocket 106inside the sachet (width W and length L) are 38 mm×60 mm.

The package, such as sachet 90, can be made of any suitable materials.Suitable package materials include films, and woven or nonwovenmaterials (in cases where the sachet contains a solid product), orlaminates of any of the foregoing. If desired, the package material cancomprise a liquid and/or vapor barrier in the form of a layer or acoating. The package materials may be comprised of non-water solublematerials, or for some uses, water soluble materials. The variousportions of the sachet (or other type of package) can all be made of thesame materials. In other embodiments, different portions of the packagecan be made of different materials. In one embodiment, the sachet 90 ismade of two pieces of the same film that form the front 92 and back 94of the sachet. The film can be any suitable type of film includingsingle layer films and laminates.

In one embodiment, the package material is a laminate comprising thefollowing three layers: a 9 micron thick polyethylene terephthalate(PET) film; an 18 micron thick vacuum metalized bi-axially orientedpolypropylene (VM BOPP) vapor barrier film; and a 30-50 micron thickpolyethylene (PE) film. The PET and PE layers are adhered to the VM BOPPfilm by adhesives. In this film, the PET layer will comprise the outsidesurface of the sachet, and the polyethylene layer will comprise asealing layer on the inside of the sachet. The water vapor barrierproperties for this film are important to prevent water loss from theproduct inside the sachet over time before it is used by the consumer.The film has a target water vapor transmission rate of less than orequal to about 0.4 grams/m²/day. The average machine direction modulusof this laminate film is about 63,000 N/m, and the average cross-machinedirection modulus is about 75,000 N/m.

FIG. 10 shows a vertical form, fill, and seal (VFFS) process andapparatus 114 for making sachets. As shown in FIG. 10, two webs ofmaterial 10 and 12 for forming the sachets are brought into theapparatus, and are fed into the process in a vertically downwarddirection. A filling tube 116 is disposed between the webs 10 and 12when the webs pass through a dispensing zone. A nozzle 118 is located atthe end or tip of the filling tube 116 (the view of the nozzle 118 isobstructed by the second web 10. Vertical seals are formed along thesides of the webs 10 and 12 by vertical sealing mechanisms 120. A cross(or cross-machine direction) sealing mechanism 122 is located below thefilling nozzle 118. The cross sealing mechanism 122 forms the seal thatis located at the top of one sachet and the bottom of the next sachet.The nozzle 118 may dispense a product such as a liquid (or paste)product in between webs 10 and 12 after the initial horizontal seal isformed at the bottom of the package. A perforation or cutting mechanism124 may be located between the upper and lower portions of the crosssealing mechanism 122 (as shown in FIG. 10), or it may be located belowthe cross sealing mechanism 122. The perforation mechanism 124 formsperforations 126 through the seal formed by the cross sealing mechanism122. A finished package or sachet 90 is shown at the bottom of FIG. 10.

The simplified version of the apparatus 114 shown in FIG. 10 is only asingle lane (one package width) wide. It is known to provide suchapparatuses with multiple side-by-side lanes. Currently, in suchapparatuses, the webs 10 and 12 will typically originate from a singleroll of web material. The web taken from the initial roll of webmaterial is slit in half, inverted over two turn bars, and run overidler rolls 130 and 132. As shown in FIG. 10, the webs 10 and 12 arebrought into the apparatus in a substantially flat configuration. Thatis, the webs 10 and 12 are generally planar across their widths. Afterturning around the idler rolls 130 and 132, the first and second webs ofmaterial 10 and 12 are generally parallel to each other with theirsealing surfaces facing each other. The first and second webs ofmaterial 10 and 12 are generally parallel to each other in the region ofthe nozzle(s) 118. Current processes typically rely on the webs ofmaterial 10 and 12 spreading apart when they pass around the nozzles 118in order to create a space into which the product is dispensed by thenozzles 118.

When the webs are formed to create a space for the nozzles and productin this manner, it can lead to variable machine direction tension acrossthe width of the webs. For example, the outside edges of the webs 10 and12 are tighter than the centerline of the webs because of the reducedweb width of the formed webs. In addition, if there are multipleside-by-side lanes, within each lane the webs are tighter in the sealbar 120 contact area than around the nozzles 118 due to the longer pathlength the webs take. This can lead to issues with lane to lane webforming-instability as a function of machine direction tension variationacross the width of the web. For example, the web in the center of themachine where it is wrapped around the nozzles is the shortest web pathlength across the width of the web, thereby making the center lanes themost unstable for forming. This may lead to various problems. Forinstance, the configuration taken by the front and back webs may not bethe same in a given lane. Ultimately, this causes a greater chance forwrinkles to form in the cross-machine direction seals of a sachet. Inaddition, if there is writing on the sachets, wrinkles may also disruptthe text making it difficult to read.

(2) Forming the Web(s)

FIG. 11 shows an apparatus having multiple lanes L1, L2, . . . to L12 inthe cross-machine direction. This enables side-by-side rows of sachetsto be produced from a single web of film (that is, a single first web ofmaterial 10 and a single second web of material 12). The VFFS apparatusdescribed herein can comprise any suitable number of multiple lanes,from two to twelve, or more. The method of making unit dose packagesdescribed herein provides a forming apparatus 20 for at least one of thewebs 10 and 12. However, it is typically desirable to provide a formingapparatus for both of the webs 10 and 12. In such case, each of the websis run through one of the forming apparatuses 20 and 20′ of the typedescribed herein. The forming apparatuses 20 and 20′ may be oriented atany suitable angle(s), (that is, in any suitable orientation) relativeto the horizontal and vertical directions. Suitable orientations canrange from substantially vertical to substantially horizontal. In theversion of the process shown in FIG. 11, the forming apparatuses 20 and20′ are oriented substantially horizontally, with the webs 10 and 12being fed into the process from opposite directions. The webs 10 and 12are brought closer together as they pass through the forming apparatuses20 and 20′, and are turned vertically downward and fed into the fillingzone around filling tubes 116 with the nozzles 118 thereon. Verticalsealing mechanisms 120 are shown at the bottom of the figure.

The forming apparatuses 20 and 20′ are used to form the webs 10 and 12into more consistent shaped configuration instead of using the nozzlesas the forming tools. The risk of leaks and defects may be greatlyreduced using this technology. The forming apparatuses 20 and 20′comprise forming guides 22 (and 22′) as described above. The formingguides 22 and 22′ have surfaces that are configured to space at least aportion of the webs 10 and 12 away from the nozzles. The forming guides22 and 22′ may be shaped to maintain even strain on the web. The formingguides 22 and 22′ can be used to form the webs 10 and 12 into anydesirable shape including, but not limited to a pleated configuration.

FIG. 12 shows one example of the cross-section of the webs 10 and 12 inthe filling zone surrounding the nozzles 118. As shown in FIG. 12, thebottoms of the valleys and the peaks of the pleats are defined bytemporary fold lines running in the machine direction. The portions ofthe webs on either side of the temporary fold lines may form anysuitable angle, A5, with each other when the webs are viewed looking inthe machine direction. Suitable angles A5 include, but are not limitedto between about 45° (or less) and less than about 180°. The fold linesof the webs are aligned. That is, the fold lines of web 10 are alignedwith the fold lines of web 12. The folded portions are aligned so thatportions of the pleats oppositely disposed on each side of the nozzles118 create space for the nozzles. In the case of forming webs for unitdose package, it may be desirable that the pleats are only temporarilyformed and that no creases are formed in the webs. The pleats mayflatten out after such temporarily pleated portions of the webs movebeyond the nozzle(s). It is understood that FIG. 12 shows only onepossible configuration of the webs 10 and 12, and that numerous otherconfigurations are possible. For example, though less desirable, some ofthe benefits of the present invention may be realized if only one of thewebs 10 and 12 is formed or pleated.

The method for transforming a web from a flat configuration (as it comesfrom a roll) to a package, such as a sachet is as follows. In amulti-lane, vertical form, fill and seal sachet making process, two webs10 and 12 are brought together from opposite sides of a row of filltubes 116. As each web 10 and 12 passes through the forming apparatuses20 and 20′, the webs generally each take the shape of a pleated web withfold lines running in the machine direction. The webs maintain thisshape when they pass adjacent to the nozzles 118 and between thevertical seal bars 120. The machine direction seal forming device may bein the form of machine direction (MD)-oriented heated elements (bars)120 that are located between adjacent lanes and also laterally outsidethe first and last lanes. The sealant layers of the webs are heated totheir melting point to heat seal the same together. Portions of the websare sealed together to join the webs 10 and 12 in machine-directionregions located between the fill tubes 116. This produces a tube-likeweb structure surrounding each fill tube 116 and its associated nozzle118. The machine direction seals will form the side seals on thesachets. The tube-like web structure is later sealed withhorizontally-oriented seals, filled with product, and sealed again withhorizontal seals to form the sachets 90.

In a vertical form, fill and seal process, it may also be desirable toreduce the length of the fill tubes 116 since long, slender fill tubesare prone to damage and instability due to machine vibration. Long filltubes can also make the height of the VFFS machine too large.Instability in the fill tubes in prior art processes can result in moreweb material to be provided on the front of a sachet than for the backof the sachet, or vice versa, causing wrinkles to form in the sealareas. As shown in FIG. 11, one way to reduce the length of the filltubes 116 is to form the webs 10 and 12 into the desired pleatedconfiguration on a horizontal plane. The pleated webs 10 and 12 can thenbe passed over a turning device to turn the formed (e.g., pleated) websinto a vertically-traveling orientation for the filling process. Thiseliminates most of the vertical space that forming would have taken ifthe forming or pleating of the webs 10 and 12 had been done in avertical orientation.

(3) The Turning Guide

One challenge with turning the webs 10 and 12 is in re-directing apleated web over a turning device. To simply pass a pleated web over aconventional idler roll would buckle the structure of the pleated web,destroying its desired pleated form. Applicants have developed a betterapproach than attempting to turn pleated webs around idler rolls. Thisapproach passes at least one of the webs, and typically each of the webs10 and 12, over a fixed, specially shaped surface, such as the turningguide 140 shown in FIG. 13. The webs 10 and 12 will typically be broughtinto the VFFS apparatus from opposite directions as shown in FIG. 11.The webs 10 and 12 are each formed as described herein, and the webs 10and 12 are then turned vertically downward over its own turning guide(not shown in FIG. 11). The turning guide 140 shown in FIG. 13 turns thepleated web an angle of 45 degrees downward.

The turning guide 140 allows the pleated web(s) to be bent out of thefolded configuration of the pleated web(s). The pleated web comprisespleats having fold lines that are typically oriented in the machinedirection. The pleated web is a three dimensional structure in which thefold lines of the ridges typically lie in one plane, and the fold linesof the valleys typically line in another plane. These planes aretypically parallel. The pleated web can be considered to have a neutralaxis or pitch line. As shown in FIG. 13, the turning guide 140 allowsthe pleated web 10 to be bent in the machine direction out of theseparallel planes (that is, the pleated web is bent in the machinedirection out of the general plane of the pleated web).

The turning guide 140 has an upstream end, a downstream end, aweb-facing surface 142 having a machine direction dimension MDD, a widthW1 oriented in the cross-machine direction, and at least two sections144 and 146 disposed in the machine direction. As shown in FIG. 13, afirst section 144 of said web-contacting surface 142 of the turningguide 140 comprises a first set of alternating machine direction ridges148 and valleys 150 across the width of the turning guide 140. A secondsection 146 of the web-contacting surface 142 is a downward slopingsection that comprises a second set of alternating machine directionridges 152 and valleys 154 across the width of the turning guide 140.The turning guide 140 is configured so that the ridges 148 of the firstsection 144 are substantially aligned with the valleys 154 of the secondsection 146, and the valleys 150 of the first section 144 aresubstantially aligned with the ridges 152 of the second section 146. Inother words, the turning guide 140 has a web-contacting surface 142shaped so that a “valley” of a pleat-forming surface on the horizontalportion becomes a “peak” of a pleat-forming surface on the downwardsloping section, to ensure that the turning process follows theprinciples of equal path length folding.

When the turning guide 140 is viewed from the side looking in across-machine direction, the ridges 148 of the first set of alternatingridges and valleys define a first plane, and the ridges 152 on thesecond set of ridges and valleys define a second plane, and the secondplane is angled away from the first plane in a direction away from theportion of the web-facing surface 142 defined by the first set ofalternating ridges and valleys. When the pleated web is passed over theweb-facing surface 142 of the turning guide 140, the pleated web can bebent in the machine direction while maintaining the pleats in the web.

To achieve a 90 degree downward turn, the downward sloping portion ofthe web-facing surface of the turning guide 140 could simply be made tobe vertical, but this requires that the web 10 turn and break overfairly sharp corners, which may damage the web. To lessen the sharpcorners that the web must break over, the turning guide 140 can beshaped to break over a series of lesser angles, such as three 30 degreebreaks as shown in FIG. 14. With each 30 degree break, the valleysbecome peaks, and the peaks become valleys, preserving the equal pathlength nature of the web. It may appear in FIG. 14 that a valley on topof the forming guide still remains a valley after the first 30 degreebreak, but in fact the valley does become a peak. Such a peak can bethought of as a peak of zero machine direction length. Minimizing thepeak length keeps the turning guide 140 as compact as possible.

Numerous alternative embodiments of the turning guide 140 are possible,a non-limiting number of which are as follows. In some embodiments, theturning guide 140 can have a mating component to hold the pleated webagainst the web-facing surface of the turning guide 140. In otherembodiments, the turning guide 140 need not have a mating component. Inother embodiments, air jets and/or vacuum can be used to hold the webagainst the turning guide 140.

(4) Sealing Together Moving Webs Having Portions which are Non-Planar.

When multiple lanes of sachets are formed simultaneously from one web,the webs 10 and 12 can take on a cross-sectional configuration such asthat shown in FIG. 12. This is an example of the webs 10 and 12 in thedispensing zone before the heat sealing cross-machine sealing bars clampthe webs to form the cross-machine direction (CD) seals. One challengethat occurs with clamping the webs 10 and 12 to make the CD seals isthat wrinkles can be formed in the portions of the webs to be sealed. Asshown in the drawing sequence FIGS. 15A to 15D, when the seal bars 122and 122′ come together, the combined web is unable to spreadhorizontally to form a flat structure for sealing. FIGS. 15A-15C showthe sequence of the sealing bars 122 and 122′ coming together. FIG. 15Dshows the wrinkles in the webs that may be formed after the sealing bars122 and 122′ move back apart.

An improved method and apparatus has, therefore, been developed forsealing two moving webs of material together which have portions whichare non-planar. The non-planar portions of the web(s) of material 10 and12 are formed across the width of the web(s) of material. The non-planarportions can include, but are not limited to: folds, pleats, rugosities,and wrinkles in the webs(s). The web(s) with the non-planar portions maybe defined by fold lines that are generally oriented in the machinedirection.

The method and apparatus for sealing two moving webs of materialtogether can be used in any suitable process in which there are movingwebs of material having portions which are non-planar. Such processesinclude, but are not limited to, conventional prior art vertical form,fill, and sealing processes that use the nozzles to shape the webs, and,of course, the improved processes described herein which use formingapparatuses to shape the webs around the nozzles.

The apparatus for sealing two moving webs of material together comprisesa first component 160 and an opposing second component 162. As shown inFIGS. 16A to 16C, the first and second components 160 and 162 cancomprise the cross-machine direction sealing bars 122 and 122′ (or 122′and 122). That is, the first and second components can be the same asthe cross-machine direction sealing bars, or the cross machine directionsealing bars can comprise a portion of the first and second components160 and 162. In other embodiments, the first and second components 160and 162 can comprise separate elements from the cross-machine directionsealing bars 122 and 122′.

If the first and second components 160 and 162 are separate from thecross-machine direction sealing mechanism, at least a portion of thecross-machine direction sealing mechanism can be located upstream and/ordownstream of the first and second components 160 and 162. If thecross-machine direction sealing mechanism comprises cross-machinedirection seal-forming elements that are spaced apart from each other inthe machine direction, at least a portion of the first and secondcomponents 160 and 162 can be located between such cross-machinedirection seal-forming elements. Regardless of their location in theapparatus, typically, at least one of the first component and the secondcomponent 160 and 162 are movable toward the each other.

In the embodiment shown in FIGS. 16A to 16C, the first component 160 hasa web-contacting surface 164 with at least one recess 166 therein. Therecan be any suitable number of recesses from one to two or more. Therecess(es) 166 can be in any suitable configuration, provided that theyare suitable to perform the desired function. For example, in makingsachets, it may be desirable for the recesses 166 to be narrow enough sothat when portions of the webs are accumulated therein, the machinedirection seal width will be greater than the sum or the width of therecess 166 plus the amount of film accumulation by about at least 20% to30%. This will ensure that the cross-machine direction seals intersectwith the machine direction seals so that the finished sachets will besealed around their entire periphery. Suitable recess configurationsinclude, but are not limited to machine-direction oriented grooves andmachine-direction oriented valleys. The opposing second component 162has a web-contacting surface 168 that faces the first component 160. Thesecond component 162 comprises at least one projection, which may be inthe form of a projecting element 170 that mates with the recess 166 inthe web-contacting surface 164 of the first component 160.

The moving webs of material 10 and 12 are fed between the first andsecond components 160 and 162. A sealing mechanism 122 for sealingportions of the moving webs of material together (if not part of thefirst and second components) is located proximate the first and secondcomponents 160 and 162. The sealing mechanism 122 can be upstream of thefirst and second components 160 and 162, downstream of the first andsecond components 160 and 162, or there can be sealing mechanisms, orportions thereof, that are both upstream and downstream of the first andsecond components 160 and 162. In the embodiment shown in FIGS. 16A to16C, the sealing mechanism is part of the first and second components160 and 162, and is located on the surfaces of the first and secondcomponents.

As shown in FIGS. 16A to 16C, the projecting elements 170 on theweb-facing surface 168 of the second component 162 can be retractableand spring-loaded to push sections of the webs into recesses (e.g.,grooves) 166 prior to sealing. The retractable, spring-loaded projectingelements 170 are formed by joining the projecting elements 170 tosprings 172 that are located in recesses 174 in the web-facing surface168 of the second component 162. By adding spring-loaded features whichpush sections of the webs into grooves 166 prior to sealing, the excessportions of the webs in the areas to be sealed can be stretched outbefore the seal bars make contact with the webs.

The sequence of events is shown in FIGS. 16A to 16C. FIG. 16A shows thefirst and second components with sealing bars thereon starting to cometogether to form a cross-machine direction seal between the sachets tobe formed. As shown in FIG. 16A, two sachets are being formed. In thisparticular embodiment, the recesses 166 and the projecting elements 170are aligned in the space between the formed portions of the webs 10 and12. (In other embodiments, this need not be necessary.) The projectingelements 170 extend outward from the web-contacting surface 168 of thesecond component 162 toward the recesses 166. FIG. 16B shows the firstand second components 160 and 162 after they have moved together closeenough that the projecting elements 170 push the webs into the recesses166. As shown by the arrows around the projecting elements 170, thiscauses portions of the webs adjacent to the projecting elements 170 andrecesses 166 to be pulled toward the projecting elements 170 andflattened out. FIG. 16C shows the first and second components 160 and162 at the stage in which their faces are brought together with the webstherebetween in order to form the cross-machine direction seal. At thisstage, the spring-loaded projecting elements 170 retract into recesses174 in the face of the second component 162.

The steps of: (1) forcing at least portions of the webs into at leastone recess 166 in the web-contacting surface of the first component 160in order to stretch and flatten at least some of the non-planar portionsof the webs; and (2) sealing portions of the first and second webstogether across the flattened non-planar portions can occur in anyorder, such as with step (1) taking place before step (2), or with steps(1) and (2) taking place simultaneously, provided that the step (1) offorcing at least portions of the webs into at least one recess 166 inthe web-contacting surface of the first component 160 occurs before theseal formed in sealing step has finished setting.

FIG. 17 shows an alternative embodiment of an apparatus for forming thecross-machine direction seals. In FIG. 17, the apparatus comprises firstand second components 180 and 182. Each of the components 180 and 182has a three-dimensional sealing surface 184 and 186, respectively,having a plurality of projections and a plurality of recesses therein.The projections and recesses on the first and second components 180 and182 are complementary, and at least some of the opposing projections andrecesses mate with one another. The mating projections and recesses canbe in any suitable configuration. In the embodiment shown, the sealingsurfaces 184 and 186 of the first and second components 180 and 182 havea sinusoidal wave configuration wherein the crests of the waves extendin the longitudinal direction. When the webs 10 and 12 (not shown) arein their pleated configuration, before the cross-machine direction sealis made, the distance from one edge of each web to the opposite edge ofeach web is less than the width of the flat web. In order to avoidhaving extra material in some places between the sealing components thatcould form a wrinkle, the sealing surfaces 184 and 186 are configured sothat the cross-machine direction length of the sinusoidal path along thesealing surfaces 184 and 186 is equivalent to the width of the flatwebs. There can be any suitable number of sinusoidal cycles per package(e.g., sachet) to be formed, from one to two or more. The sealingsurfaces 184 and 186 can also be coated with any suitable coating.

(5) Filling the Sachets

In the case of the process of making sachets, a first cross-machinedirection seal is made to form the bottom of the sachet. A product isdispensed into the open top of the sachet. The product can be dispensedafter the seal is made to form the bottom of the sachet. In otherembodiments, the product can be dispensed shortly before the seal ismade to form the bottom of the sachet for maximum line speed (since ittakes a small amount of time for the product to flow down to the sealarea). The product can be dispensed with any suitable dispensing deviceor apparatus. Suitable devices include, but are not limited to nozzles,positive displacement pumps, and devices for dispensing solids orpowders, depending on the product to be dispensed. Although the presentdescription describes nozzles, other dispensing devices may be usedinstead.

The nozzles 118, and the orifices thereof, can be of any suitable typeand configuration. One suitable nozzle is a Hibar Double Acting FillTube Assembly (⅜″ ID) circular orifice positive shut off nozzle having adispensing orifice diameter of ¼ inch (6.4 mm) available from HibarSystems Limited of Toronto, Canada. In other embodiments, the nozzle mayhave multiple orifices. That is, the nozzle may be a multiple-hole or“multi-hole” nozzle. Examples of multi-hole nozzles are described inU.S. patent application Ser. No. 14/028,877 filed Sep. 17, 2013. Thedischarge end of the nozzle assembly and nozzle component may have anysuitable configuration(s). For example, when a multi-hole nozzle is usedin a vertical forming, filling and sealing process, it may be desirablefor the discharge end of the multi-hole nozzle to have a flattenedshape, such as a flattened diamond shape, so that it is betterconfigured to fit in the space between the two webs of material used toform the packages.

There can be any suitable number of nozzles 118 from a single nozzle tomultiple nozzles. As shown in FIG. 11, multiple nozzles can be providedin the cross-machine direction (CD) in an apparatus that comprisesmultiple CD lanes for forming packages. If there are multipleside-by-side lanes, there can be any suitable number of lanes including,but not limited to from two to twelve or more lanes. The multiplenozzles 118 can be substantially aligned, such as in rows in the CD.

The nozzles 118 may be stationary or movable. It is not conceded that amovable nozzle mechanism is part of the prior art. As shown in FIG. 10,if a moveable nozzle mechanism is used in a vertical forming, fillingand sealing (VFFS) process, the nozzles 118 could move vertically upwardand downward in the direction of the arrow. The nozzles 118 may move ata constant speed or at a variable speed during dosing. If the speed ofthe nozzles is variable, the movement of the nozzles may accelerate ordecelerate during dosing.

It is desirable for each dose of liquid to be dispensed cleanly into thepackage and to substantially immediately stop the flow of liquid betweendoses. If the dispensing nozzle 118 drips or produces product stringsbetween doses, the seal area between doses can be contaminatedpotentially causing a failure of the seal and a leaky sachet. Control ofthe dosing is accomplished by using a filling system or fill controlsystem. Examples of filling (or dosing) systems with a filling controlsystem are described in U.S. patent application Ser. Nos. 13/776,753 and13/776,761, filed on Feb. 26, 2013.

A vertical form, fill, and sealing (VFFS) apparatus 114 such as thatshown in FIG. 10 can have stationary nozzles 118 and stationary sealbars 120 and 122 while the machine is running. However, the nozzles 118may need to be able to move up and down in the event it is desired tochange the sachet length. This is a setup change that may be made whenthe machine is not running. In one embodiment, the MD seal bars 120 canbe fixed on one side of the webs, with the surface of the fixed MD sealbars in a plane that is aligned with the centerline of the nozzle 118.The opposing MD seal bars 120 can be spring loaded up against the fixedseal bars with the webs 10 and 12 in between. The nozzles 118 may, forexample, remain fixed at a nominal 20-90 mm above the initial contactpoint of the CD sealing bar 122, depending on sachet length, and fillvolumes.

When more process adjustment is needed, the MD seal bars 120, nozzles118, or both could move up and down in conjunction with the downwardmotion of the webs 10 and 12. The MD seal bars 120 could move straightup and down. Alternatively, the MD seal bars 120 could move in asemi-elliptical motion, spreading apart about 1 mm, just enough to losecontact with the webs 10 and 12. The bars 120 could then contact thefilm, move down a distance, such as from about 5 to about 50 percent ofthe sachet length, with their movement matched with the film speed, thenretract and return to the starting contact position. It is desirablethat the motion and length of the seal bars are designed to ensure thatthere is a contiguous MD seal between what will be successive sachetsprior to cutting the webs into individual sachets.

Further, the nozzles 118 can be moved such that the nozzle tip 118always remains at a fixed distance from the fill target. For example, ifthe bottom of the sachet is located 25 mm below the tip 118 of thenozzle 118 when the filling starts, the nozzle 118 could retract upwardas the filling progresses such as to maintain at least the 25 mm spacingfrom the tip 118 of the nozzle 118 to the top of the fluid patch. Thenozzle 118 could then retract faster upward at the end of the fill toallow for the CD sealer 42 to close. One other alternative for nozzlemovement would be to have the nozzles 118 spaced farther away from theCD seal bar 122 when the seal is first made to reduce the deformation inthe sachet. The tip 118 of the nozzle 118 could then lower into thesachet once the CD seal process has been initiated to progress throughthe bottom-up fill sequence described above.

The process for making the sachets may comprise an apparatus for formingmachine direction slits and an apparatus for cross machine directionperforation/cutting. The apparatus for forming machine direction slitsand the apparatus for cross machine direction perforation/cutting may belocated upstream, or downstream of the cross-machine direction sealingdevice 122. For example, the apparatus for forming machine directionslits may be located upstream of the cross-machine direction sealingdevice 122, and the apparatus for cross machine directionperforation/cutting may be located downstream of the cross-machinedirection sealing device 122. The machine direction slitting can be doneby any suitable mechanism 126, including but not limited to by a crushslitter against an anvil or by a shear slitting apparatus. The web ofunit dose packages can be slit between each lane or otherwise asdesired. The slits can be continuous or they can be intermittentperforations. The cross machine direction perforation process can bedesigned and operated to cut between specified rows to make mats(matrices of products). Mechanical tooling can be used for both themachine direction slitting apparatus and the cross-machine directionslitting apparatus. However, laser slitting in the machine direction orcross machine direction can be utilized. After the slitting andperforation/cutting operations are completed, the production of thesachets is complete.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An apparatus for sealing two moving webs ofmaterial together, wherein said webs are moving in a machine directionand said webs have a width, and said webs of material have portionswhich are non-planar across their width, said apparatus comprising: a) afirst component having a web-contacting surface configured to contact atleast one of the two moving webs the first component having at least onerecess in the web-contacting surface; b) a second component opposingsaid first component and having a web-contacting surface configured tocontact at least one of the two moving webs, said second componentcomprising at least one projection that mates with said at least onerecess in the web-contacting surface of said first component, the movingwebs of material being located between webs of material between thefirst and second components; and c) a sealing mechanism located on orproximate to said first and second components, said sealing mechanismbeing configured to seal portions of said moving webs of materialtogether; wherein said at least one projection and said at least onerecess are positioned and configured to stretch said two moving webswhen said at least one projection mates with said at least one recess,said at least one projection and said at least one recess beingconfigured to not seal together said two moving webs.
 2. The apparatusof claim 1 wherein said sealing mechanism is configured to form across-machine direction oriented seal across said webs of material. 3.The apparatus of claim 2 wherein at least a portion of said sealingmechanism is located upstream of said first and second components. 4.The apparatus of claim 3 wherein at least a portion of said sealingmechanism is located downstream of said first and second components. 5.The apparatus of claim 2 wherein at least a portion of said sealingmechanism is located downstream of said first and second components. 6.The apparatus of claim 2 wherein said sealing mechanism comprises a pairof cross-machine direction seal-forming elements, wherein saidcross-machine direction seal-forming elements are spaced apart in themachine direction, and at least a portion of said first and secondcomponents are located between the cross-machine direction seal-formingelements in the machine direction.
 7. The apparatus of claim 1 whereinsaid sealing mechanism is located on at least one of said first andsecond components and at least one of said first or second components ismovable toward the other of said first or said second component so thatwhen said first or second component moves toward the other of said firstor second component, it both flattens said non-planar portions and formsa seal.
 8. The apparatus of claim 1 wherein said at least one projectioncomprises a projecting element that is spring-loaded.
 9. The apparatusof claim 1 wherein the web-contacting surfaces of said first and secondcomponent have a sinusoidal wave configuration having crests, whereinthe crests of the waves extend in the machine direction.